Tool Wear of Multi-Layer AlCrWN/AlCrWSiN-Coated Cemented Carbide in Cutting Hardened Sintered Steel

In order to clarify the effectiveness of the multi-layer AlCrWN/AlCrWSiN-coated cemented carbide tool, the wear progress was investigated in cutting hardened sintered steel using three types of coated tool. Namely, Tool I had the dual-layer (Al60,Cr25,W15)(C,N)/(Al53,Cr23,W14,Si10)(C,N)-coating film, Tool II had the multi-layer (Al60,Cr25,W15)(C,N)/(Al53,Cr23,W14,Si10)(C,N)-coating film and Tool III had the multi-layer (Al60,Cr25,W15)N/(Al53,Cr23,W14,Si10)N-coating film. The following results were obtained: (1) The main tool failure of the three types of coated tools were the flank wear within the maximum value of the flank wear width of 0.2 mm. (2) The critical scratch load of the three types of coated tools was 130 N or more. (3) The micro-hardness of Tool III 3000 HV0.25N was the highest among the three types of coated tools. (4) The mean value of the friction coefficient of the (Al53,Cr23,W14,Si10)N coating film, 0.21, was approximately half that of the (Al53,Cr23,W14,Si10)(C,N) coating film, 0.41. (5) In the case of the higher cutting speed, the wear progress of the multi-layer coating system was slower than that of the dual-layer coating system. (6) In the case of the cutting hardened sintered steel using the multi-layer coated tool, the wear progress of the Type III coated tool was slower than that of the Type II coated tool.

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Tool Wear of Aluminum/Chromium/Tungsten-Based-Coated Cemented Carbide in Cutting Hardened Sintered Steel

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.772.72 ◽

2015 ◽

Vol 772 ◽

pp. 72-76 ◽

Cited By ~ 1

Author(s):

Tadahiro Wada ◽

Hiroyuki Hanyu

Keyword(s):

Tool Wear ◽

Cathode Material ◽

Cutting Speed ◽

Cemented Carbide ◽

Coating Film ◽

Sintered Steel ◽

High Cutting Speed ◽

Coated Tools ◽

Coated Tool ◽

Coated Cemented Carbide

In order to improve both the scratch strength and the micro-hardness of (Al,Cr)N coating film, the cathode material of an aluminum/chromium/tungsten target was used in adding the tungsten (W) to the cathode material of the aluminum/chromium target. In this study, hardened sintered steel was turned with (Al60,Cr25,W15)N, (Al60,Cr25,W15)(C,N), (Al64,Cr28,W8)(C,N), (Al,Cr)N and (Ti,Al)N coated cemented carbide tools. The tool wear of the coated cemented carbide tool was experimentally investigated. The following results were obtained: (1) In cutting hardened sintered steel at the cutting speed of 0.42 m/s using the (Al60,Cr25,W15)N, the (Al60,Cr25,W15)(C,N), the (Al64,Cr28,W8)(C,N), the (Ti,Al)N and (Al,Cr)N coated tools, the wear progress of the (Al64,Cr28,W8)(C,N) coated tool became slowest among that of the five coated tools. (2) The wear progress of the (Al60,Cr25,W15)(C,N) coated tool was almost equivalent to that of the (Al64,Cr28,W8)(C,N) coated tool. However, at a high cutting speed of 1.67 m/s, the wear progress of the (Al60,Cr25,W16)(C,N) coated tool was faster than that of the (Al64,Cr28,W8)(C,N) coated tool.

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Wear Mechanism of Multi-layer AlCrWN/AlCrWSiN Coatings on Cemented Carbide Tool Prepared by Arc Ion Plating in Dry Cutting of Sintered Steel

MATEC Web of Conferences ◽

10.1051/matecconf/201927802001 ◽

2019 ◽

Vol 278 ◽

pp. 02001

Author(s):

Tadahiro Wada ◽

Hiroyuki Hanyu

Keyword(s):

Flank Wear ◽

Main Tool ◽

Cemented Carbide ◽

Coating Film ◽

Sintered Steel ◽

Dry Cutting ◽

Mono Layer ◽

Cemented Carbide Tool ◽

Cemented Carbide Tools ◽

Coated Cemented Carbide

To clarify the effectiveness of multi-layer AlCrWN/AlCrWSiN-coated cemented carbide tools, the wear progress was investigated in cutting sintered steel using three types of coated tool. Tool I had a mono-layer (Al60,Cr25,W15)N-coating film, Tool II had a mono-layer (Al53,Cr23,W14,Si10)N-coating film and Tool III had a multi-layer (Al60,Cr25,W15)N/(Al53,Cr23,W14,Si10)N-coating film. The following results were obtained: (1) The main tool failure of the three types of coated tools was flank wear within a maximum value of flank wear width of 0.2 mm. (2) The wear progress of Type III, which was a multi-layer coating system, was the slowest in cutting sintered steel.

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Experimental Study on Turning Nickel-Based Superalloy GH4033 with Coated Cemented Carbide Tools

Materials Science Forum ◽

10.4028/www.scientific.net/msf.800-801.191 ◽

2014 ◽

Vol 800-801 ◽

pp. 191-196

Author(s):

Bin Zhao ◽

Han Lian Liu ◽

Chuan Zhen Huang ◽

Bin Zou ◽

Hong Tao Zhu

Keyword(s):

Surface Roughness ◽

Tool Life ◽

Failure Modes ◽

Flank Wear ◽

Cutting Performance ◽

Cemented Carbide ◽

Nickel Based Superalloy ◽

Coated Tool ◽

Optimal Cutting Parameters ◽

Coated Cemented Carbide

The nickel-based superalloy GH4033 is one of the difficult-to-cut materials. In order to investigate the machinability of GH4033, the tool cutting performance, tool failure modes, tool life and the relationships between surface roughness and tool flank wear were studied by using different coated cemented carbide cutting tools under dry cutting. Aiming at the amount of metal removal combining with the tool life and surface quality, the better cutting tool coating type and optimal cutting parameters were obtained through the orthogonal experiments. The results showed that the cutting performance of TiCN coated tool (GC4235) was better than that of TiAlN coated tool (JC450V). With these two kinds of tools, the machined surface roughness decreased to a minimum value and then increased with the increase of flank wear. When cutting GH4033, the main wear mechanism for both of the two types of tools included adhesive wear, diffusive wear, abrasive wear, edge wear and coating peeling.

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Performance of Titanium-Tungsten-Silicon-Aluminum Based Coated Cutting Tools

Materials Science Forum ◽

10.4028/www.scientific.net/msf.561-565.1241 ◽

2007 ◽

Vol 561-565 ◽

pp. 1241-1244 ◽

Cited By ~ 1

Author(s):

Tadahiro Wada

Keyword(s):

Carbon Steel ◽

Low Carbon Steel ◽

Carbon Steels ◽

Cemented Carbide ◽

Coating Film ◽

Low Carbon ◽

Tin Coating ◽

Coating Films ◽

Coated Tool ◽

Coated Cemented Carbide

In order to determine an effective coating film for cutting carbon steels with a coated cemented carbide tool, tool wear was experimentally investigated. Low carbon steel (AISI 5120H steel) was turned with four kinds of physical vapor deposition (PVD) coated cemented carbide tools. The coating films used were TiN coating film and three kinds of titanium-tungsten-silicon-aluminum based coating films, namely (Ti,W,Si,Al)N, (Ti,W,Si,Al)C and (Ti,W,Si,Al)(C,N) coating film. (Ti,W,Si,Al)N, (Ti,W,Si,Al)C or (Ti,W,Si,Al)(C,N) is a new type of coating film. The following results were obtained: (1) The critical load of three kinds of titanium-tungsten-silicon-aluminum based coating films was higher than that of TiN coating film. (2) The hardness of three kinds of titanium-tungsten-silicon-aluminum based coating films was higher than that of TiN coating film. (3) In cutting low carbon steel, the wear progress of three kinds of titanium-tungsten-silicon-aluminum based coating film tools was slower than that of the TiN coated tool. (4) In the three kinds of titanium-tungsten-silicon-aluminum based coating films, the wear progress of the (Ti,W,Si,Al)N coated tool was the slowest.

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Experimental research method when developing a mathematical model for calculating cutting speed in the course of turning steels with a coated tool

MATEC Web of Conferences ◽

10.1051/matecconf/201929800134 ◽

2019 ◽

Vol 298 ◽

pp. 00134

Author(s):

Zhanna Tikhonova ◽

Evgeniy Frolov ◽

Dmitriy Krainev ◽

Alexander Plotnikov

Keyword(s):

Mathematical Model ◽

Experimental Study ◽

Experimental Research ◽

Research Method ◽

Cutting Speed ◽

Coated Tools ◽

Coated Tool ◽

Cutting Zone

The article is devoted to the description of the experimental research method when developing a mathematical model for calculating the cutting speed based on information from the cutting zone obtained during the test run in the process of turning using steel coated tools as an example. This paper also presents the results of an experimental study which prove the effectiveness of applying the obtained mathematical dependence.

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Cutting Performance Evaluation of the Coated Tools in High-Speed Milling of AISI 4340 Steel

Materials ◽

10.3390/ma12193266 ◽

2019 ◽

Vol 12 (19) ◽

pp. 3266 ◽

Cited By ~ 4

Author(s):

Yuan Li ◽

Guangming Zheng ◽

Xiang Cheng ◽

Xianhai Yang ◽

Rufeng Xu ◽

...

Keyword(s):

Performance Evaluation ◽

Cutting Force ◽

High Speed ◽

Cutting Temperature ◽

Cutting Speed ◽

Cutting Performance ◽

High Speed Milling ◽

Coated Tools ◽

Coated Tool ◽

Aisi 4340

The cutting performance of cutting tools in high-speed machining (HSM) is an important factor restricting the machined surface integrity of the workpiece. The HSM of AISI 4340 is carried out by using coated tools with TiN/TiCN/TiAlN multi-coating, TiAlN + TiN coating, TiCN + NbC coating, and AlTiN coating, respectively. The cutting performance evaluation of the coated tools is revealed by the chip morphology, cutting force, cutting temperature, and tool wear. The results show that the serration and shear slip of the chips become more clear with the cutting speed. The lower cutting force and cutting temperature are achieved by the TiN/TiCN/TiAlN multi-coated tool. The flank wear was the dominant wear form in the milling process of AISI 4340. The dominant wear mechanisms of the coated tools include the crater wear, coating chipping, adhesion, abrasion, and diffusion. In general, a TiN/TiCN/TiAlN multi-coated tool is the most suitable tool for high-speed milling of AISI 4340, due to the lower cutting force, the lower cutting temperature, and the high resistance of the element diffusion.

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Study on the Coated Tool Wear Mechanism of High Speed Milling Ni-Base Superalloy GH625

Materials Science Forum ◽

10.4028/www.scientific.net/msf.723.311 ◽

2012 ◽

Vol 723 ◽

pp. 311-316

Author(s):

Wei Wang ◽

Ming Hai Wang ◽

Xiao Peng Li

Keyword(s):

Wear Mechanisms ◽

High Speed ◽

High Speed Milling ◽

Coated Tools ◽

Coated Tool ◽

Tool Wear Mechanism ◽

Cemented Carbide Tools ◽

Tools Wear ◽

Coated Cemented Carbide ◽

Base Superalloy

The experiments of high speed milling Ni-base superalloy GH625 by using two types of the coated cemented carbide tools at home and abroad, using the scanning electron microscopy (SEM) to observe the tools wear morphology, analyzing the worn surface elements distribution by energy spectrum analysis (EDS) and the main wear mechanisms of the tools. The results show that adhesion, oxidation and diffusion are the main wear mechanisms in initiative wearing stage of the domestic coated tools. And the main wear mechanisms of the imported coated tools are adhesion, oxidation, diffusion and coating spallation.

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Tool Wear of Aluminum/Chromium/Tungsten-Based-Coated Cemented Carbide in Cutting Hardened Steel

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.798.377 ◽

2015 ◽

Vol 798 ◽

pp. 377-383 ◽

Cited By ~ 4

Author(s):

Tadahiro Wada ◽

Hiroyuki Hanyu

Keyword(s):

Tool Wear ◽

Cathode Material ◽

Hardened Steel ◽

Cemented Carbide ◽

Coating Film ◽

Carbide Tool ◽

Micro Hardness ◽

Cemented Carbide Tools ◽

Coated Carbide ◽

Coated Cemented Carbide

An aluminum/chromium based coating film, called (Al,Cr)N coating film, has been developed. This coating film has a slightly more inferior critical scratch load and micro-hardness. Therefore, to improve both the scratch strength and micro-hardness of the (Al,Cr)N coating film, the cathode material of an alumi-num/chromium/tungsten target was used in adding the tungsten (W) to the cathode material of the alumi-num/chromium target. To clarify the effectiveness of the aluminum/chromium/tungsten-based coating film, we measured the thickness, micro-hardness and critical scratch strength of aluminum/chromium/tungsten-based coating film formed on the surface of a substrate of cemented carbide ISO K10 formed by the arc ion plating process. The hardened steel ASTM D2 was turned with the (Al,Cr,W)N, (Al,Cr,W)(C,N), (Al,Cr)N and the (Ti,Al)N coated cemented carbide tools. The tool wear of the coated cemented carbide tools was ex-perimentally investigated. The following results were obtained: (1) The micro-hardness of the (Al,Cr,W)N or (Al,Cr,W)(C,N), (Al,Cr)N coating film was 3110 HV0.25N or 3080 HV0.25N, respectively. (2) The critical scratch load of the (Al,Cr,W)(C,N) coating film was 123 N, which was much higher than that of the (Al,Cr)N or (Ti,Al)N coating film. (3) In cutting the hardened steel using (Al,Cr,W)(C,N) and (Ti,Al)N coated carbide tools, the wear progress of the (Al,Cr,W)(C,N) coated carbide tool was almost equivalent to that of the (Ti,Al)N coated carbide tool. The above results clarify that the aluminum/chromium/tungsten-based coating film, which is a new type of coating film, has both high hardness and good adhesive strength, and can be used as a coating film of WC-Co cemented carbide cutting tools.

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Investigation of Cutting Temperature during Turning Inconel 718 with (Ti,Al)N PVD Coated Cemented Carbide Tools

Materials ◽

10.3390/ma11081281 ◽

2018 ◽

Vol 11 (8) ◽

pp. 1281 ◽

Cited By ~ 8

Author(s):

Jinfu Zhao ◽

Zhanqiang Liu ◽

Qi Shen ◽

Bing Wang ◽

Qingqing Wang

Keyword(s):

Physical Properties ◽

Inconel 718 ◽

Great Influence ◽

Cutting Temperature ◽

Cemented Carbide ◽

Machining Process ◽

Coated Tools ◽

Cemented Carbide Tools ◽

Coated Cemented Carbide ◽

Thermo Physical Properties

Physical Vapor Deposition (PVD) Ti1−xAlxN coated cemented carbide tools are commonly used to cut difficult-to-machine super alloy of Inconel 718. The Al concentration x of Ti1−xAlxN coating can affect the coating microstructure, mechanical and thermo-physical properties of Ti1−xAlxN coating, which affects the cutting temperature in the machining process. Cutting temperature has great influence on the tool life and the machined surface quality. In this study, the influences of PVD (Ti,Al)N coated cemented carbide tools on the cutting temperature were analyzed. Firstly, the microstructures of PVD Ti0.41Al0.59N and Ti0.55Al0.45N coatings were inspected. The increase of Al concentration x enhanced the crystallinity of PVD Ti1−xAlxN coatings without epitaxy growth of TiAlN crystals. Secondly, the mechanical and thermo-physical properties of PVD Ti0.41Al0.59N and Ti0.55Al0.45N coated tools were analyzed. The pinning effects of coating increased with the increasing of Al concentration x, which can decrease the friction coefficient between the PVD Ti1−xAlxN coated cemented carbide tools and the Inconel 718 material. The coating hardness and thermal conductivity of Ti1−xAlxN coatings increased with the increase of Al concentration x. Thirdly, the influences of PVD Ti1−xAlxN coated tools on the cutting temperature in turning Inconel 718 were analyzed by mathematical analysis modelling and Lagrange simulation methods. Compared with the uncoated tools, PVD Ti0.41Al0.59N coated tools decreased the heat generation as well as the tool temperature to reduce the thermal stress generated within the tools. Lastly, the influences of Ti1−xAlxN coatings on surface morphologies of the tool rake faces were analyzed. The conclusions can reveal the influences of PVD Ti1−xAlxN coatings on cutting temperature, which can provide guidance in the proper choice of Al concentration x for PVD Ti1−xAlxN coated tools in turning Inconel 718.

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